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2019 passport corrosion!!!!!

4995 Views 25 Replies 16 Participants Last post by  novabus, 
C
This picture is the structural support for the dash in the drivers side floorpan on the right side. It is an aluminum support bolted to the steel floor. It has completely corroded and is now longer attached to the floor. I would think this is a case of dissimilar metals. My concern is where else is this happening on this vehicle that I can't see?? I thought it was a salt stain on the edge of the carpet until I removes the kick panel to see this. Vehicle has been on the road for 30 months, with 27k kms. Anyone else around have this issue? I would assume both pilot and Ridgeline are the same setup. Worth removing the kick panel to look. Look just below the lower bolt and you will see the edge of the aluminum end, and the powder start.
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L
Conradb said:
This picture is the structural support for the dash in the drivers side floorpan on the right side. It is an aluminum support bolted to the steel floor. It has completely corroded and is now longer attached to the floor. I would think this is a case of dissimilar metals. My concern is where else is this happening on this vehicle that I can't see?? I thought it was a salt stain on the edge of the carpet until I removes the kick panel to see this. Vehicle has been on the road for 30 months, with 27k kms. Anyone else around have this issue? I would assume both pilot and Ridgeline are the same setup. Worth removing the kick panel to look. Look just below the lower bolt and you will see the edge of the aluminum end, and the powder start. View attachment 14769
View attachment 14768
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WOW!!! NOT A GOOD THING!!! Keep us in the loop on what Honda's response is...larryd
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C
I wonder if the OEM Warranty covers this?
Initially, I'd think so, but this isn't your father's Honda Company.
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B
Yikes! Hopefully this is an isolated instance. With well over a million current design Pilots, Ridgelines and Passports sold you would think it would be well publicized if it was a common problem.
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Dealer has ordered new support made from different material. I asked if this was a recall and the didn't know of one for this issue. The steel frame for the console is also corroded and is to be replaced. I believe I saw the cost to be about 1100$ for parts and they need 3 to 4 hrs to install. This is one part of the steel frame on the front right corner of the drivers seat. I would bet my life that this is an issue with more than just our vehicle.
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Gray_Beard
To say that you have the one vehicle that has the supports made with the wrong materials is like saying you have the purple unicorn that farts pink fairy dust out it's butt. That is complete BS. I would demand that they send a Honda engineer to view and document that before any parts get swamped out.
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Haha. I agree. But, I live on the east coast of Canada and I am quite positive that if the vehicle completely disintegrated in my driveway, no engineers would be coming here. I think I will just contact honda canada myself and let them know what is going on. Ill probably start pulling some other panels to see if I can see any other issues.
This suv has been rust checked each year since new as well.
I have a 2013 f150 with 330k on it and I completely stripped the inside last year to install leather seats and different console, and never saw any issues like this.
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I would send photos and description to Honda Canada. The problem could be more extensive with additional corrosion of the the floor pan or whatever the console frame connects to. I'd be shocked if this was a widespread problem...so it would be nice if Honda could determine the cause. Galvanic corrosion maybe but then it should be a common problem,
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fx_chip
Scary. 😨
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M
Where is the moisture even coming from? Leaky condensate line?
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J
I don't understand how they would start corroding in the first place.
Did you have wet carpet?
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fx_chip
My Honda service manual indicates that the dashboard support frame and the frame support beam that is corroding in the picture above are made from magnesium alloy as a weight saving measure. I wonder why Honda decided to go that route considering the fact that magnesium alloy is highly susceptible to macrogalvanic corrosion when coupled with other metals like steel. This type of metal corrosion is not moisture activated, what is needed is contact with another type of metal and the presence of an electrical charge passing through both metals.

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M
You are in Canada do they have an agency like USA the National Highway Safety group that issues recalls to automakers? They also need to see this and CC honda so honda is aware that you sent the pictures. I had an 04 f150 that had magnesium radiator support and in the 15 years and NE salt never had any issues with it being bolted to the steel frame. Have seen it in construction, steel armor cable and copper pipe but not in autos.
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jasonpp said:
I don't understand how they would start corroding in the first place.
Did you have wet carpet?
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Lol. Yes. We have winter 8 months of the year. Everyone has wet carpet in winter.
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NotcherBiznas
fx_chip said:
what is needed is contact with another type of metal and the presence of an electrical charge passing through both metals.
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Agree with this...there's likely some wiring issues there as well which is the ultimate cause.
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R
I would be raising hell. Do not accept that this "just a defective part." Your car should not have corrosion like this under any circumstance, no matter where you live, especially only after a few years.
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D
There has to have been some type of moisture... something for electricity to flow through between the two dissimilar metals. Did you ever spill anything (even a soda) along the side of the center console? Or is there any way at all that moisture could have gotten on the floorboard? This is bad engineering on Honda's part all the way by not putting some kind of barrier between the two metals when bolting them together. When bringing aluminum and steel into contact, you should use a thin layer of non-absorbent insulate between them. Rubber or plastic can work, depending on the application. You can also use polypropylene tape or prime the parts with a protective coating before assembly. I just don't understand how this could happen in this day an age with the engineering knowledge we have. Please keep us updated on whatever "different metal" Honda decides to use. Also, if you think of it, ask if Honda used that "different metal" in production after 2019? This is something that nightmares are made of when we spend A LOT of our hard earned money on a new vehicle. Best of luck!
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fx_chip
The dealer made a mistake by identify the offending metal as aluminum, it's magnesium. Here below is Honda's January 2019 official press release announcing the entry of the Passport into it's vehicle lineup, the press release identified the "Steering Hanger Beam" as a structure made from magnesium in several sections of the document. The Honda service manual for the Passport that I had the opportunity to briefly go through after I saw this post also identified the structure as magnesium and it called for complete replacement instead of repair if the structure ever gets damaged. I believe this will also be true for 2016+ Honda Pilot and Ridgeline.

hondanews.com

2019 Honda Passport Press Kit

2019 Honda Passport Press Kit
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M
Just did some digging and it looks like that bracket has had the same part number for: 2014-2021 MDX, 2016+ Pilot, 2017+ Ridgeline, and 2019+ Passport. I would think if this was common it would be known about by now.
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Conradb said:
Lol. Yes. We have winter 8 months of the year. Everyone has wet carpet in winter.
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Might wanna look into Husky liners or Weathertech to keep water from getting onto the carpet.
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